Percussive/rotating drill with blow-out, broken bit, and pressure loss detection systems

ABSTRACT

A drilling system includes a control system that monitors operating parameters so as to protect the drilling machine from damage and increases drilling operation efficiency. A method of using a hydraulic system of a percussive drill as a sensing system includes sensing a drill bit blow-out event by measuring changes in the operating hydraulic fluid pressure in the hydraulic system used to operate the percussive drill.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 15/280,222, filed Sep. 29, 2016; which claims benefit of U.S. Patent Provisional Application No. 62/235,099, filed Sep. 30, 2015, which applications are hereby incorporated by reference in their entireties.

BACKGROUND

In quarrying operations, large blocks of stone are often harvested from the ground. However, because the large blocks of stone are too heavy and large to transport easily, the large blocks of stone need to be methodically broken into smaller blocks so that they can be handled and transported reasonably. It is common practice in quarrying operations to use a rock drill to drill a series of spaced-apart bores/holes into the large blocks of stone so that they may be easily split while minimizing waste. However, drilling into stone/rock is a difficult task. Due to the hardness of the rock, drill bits can break during the drilling process, which can lead to downtime for the drilling machine, thereby decreasing productivity and efficiency.

Additionally, when drilling such holes close to an edge of a large block of rock, drill bits can travel out of the side (defining the edge) of the large blocks causing what is known as a blow-out event. When a blow-out event occurs, the drill bit does not tend to stay in its programmed straight path. The drill bit is forced out the side of the large rock block and is deflected in the process. Such deflection can cause the drill bit to bind in the hole and potentially break.

Improvements in systems to monitor the drill bit activity during drilling operations are needed.

SUMMARY

The present disclosure relates generally to a rock drill attachment. In one possible configuration, and by non-limiting example, the rock drill attachment is configured to monitor a variety of different operative aspects of the rock drill attachment so as to prevent damage to the rock drill attachment.

In a first aspect of the present disclosure, a method of using a hydraulic system of a percussive drill as a sensing system is disclosed. The method includes sensing a drill bit blow-out event by measuring changes in the operating hydraulic fluid pressure in the hydraulic system used to operate the percussive drill.

In a second aspect of the present disclosure, a drilling attachment configured to attach to a vehicle is disclosed. The drilling attachment includes a drill bit and a first motor for rotating the drill bit. The drilling attachment also includes a second motor for controlling the thrust applied to the drill bit. The first and second motors include hydraulic connections for attaching to an external hydraulic system. The drilling attachment further includes a drill bit blow-out sensing system operatively connected to the first and second motors. The drill bit blow-out sensing system senses a drill bit blow-out event based on a change in an operational hydraulic pressure within at least one of the first and second motors.

In a third aspect of the present disclosure, a drill bit monitoring system for a percussive drill is disclosed. The drill bit monitoring system includes a vehicle that includes an engine and a hydraulic system. The hydraulic system includes a pump at least partly powered by the engine. The vehicle further includes a boom operated by the hydraulic system. The drill bit monitoring system also includes a drilling attachment removably attached to the boom of the vehicle. The drilling attachment includes a drill bit, a first motor for rotating the drill bit, and a second motor for controlling the thrust applied to the drill bit. The first and second motors are connected to the hydraulic system of the vehicle. The drilling attachment also includes a drill bit blow-out sensing system operatively connected to the first and second motors. The drill bit blow-out sensing system senses a drill bit blow-out event based on a change in an operational hydraulic pressure within at least one of the first and second motors.

A variety of additional aspects will be set forth in the description that follows. The aspects can relate to individual features and to combinations of features. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad inventive concepts upon which the embodiments disclosed herein are based.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings are illustrative of particular embodiments of the present disclosure and therefore do not limit the scope of the present disclosure. The drawings are not to scale and are intended for use in conjunction with the explanations in the following detailed description. Embodiments of the present disclosure will hereinafter be described in conjunction with the appended drawings, wherein like numerals denote like elements.

FIG. 1 illustrates a schematic side view of a drilling system according to one aspect of the present disclosure;

FIG. 2 illustrates a schematic front view of a portion of the drilling system of FIG. 1;

FIGS. 2A-2C illustrate various perspective views of the vehicle and the drill attachment of the drilling system of FIGS. 1-2;

FIG. 3 illustrates a schematic side view of a drilling system of FIG. 1 resting on a work piece;

FIG. 4 shows a schematic block diagram of the control system of the drilling system, according to one aspect of the present disclosure;

FIG. 5 shows a schematic block diagram of the blow-out detection system according to one aspect of the present disclosure;

FIG. 6 shows a schematic block diagram of the broken drill bit detection system according to one aspect of the present disclosure;

FIG. 7 shows a schematic block diagram of the pressure loss detection system according to one aspect of the present disclosure; and

FIG. 8 schematically illustrates a circuit of an example hydraulic system for use with the drilling system of FIGS. 1-3, separated into multiple pages.

DETAILED DESCRIPTION

Various embodiments will be described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Reference to various embodiments does not limit the scope of the claims attached hereto. Additionally, any examples set forth in this specification are not intended to be limiting and merely set forth some of the many possible embodiments for the appended claims.

The drill attachment disclosed herein has several advantages. By attaching the drilling machine to a vehicle, the drill attachment becomes mobile so that it can be used in a variety of different worksite environments. Further, the drill attachment is powered by the power systems of the vehicle (i.e., hydraulic and electrical). This reduces the overall costs of the drill attachment. Additionally, the disclosed drill attachment includes a control system that configured to monitor a variety of different operational characteristics of the drill attachment during a drilling operation. Specifically, the control system is configured to monitor the activity of the hydraulic system in order to sense a blow-out event, a broken drill bit, or other system failure. Upon sensing an event, the control system is configured to alter the operation of the drill attachment so as to prevent further damage to the drill bit or drill attachment itself. In some embodiments, the control system uses preexisting sensors of the hydraulic system of the vehicle to monitor for particular events in the drilling operation.

A drilling system 100 is schematically shown in FIGS. 1 and 2. The drilling system 100 includes a vehicle 102 and a drill attachment 104. The drill attachment 104 is removably attached to and operable by the vehicle 102. The drilling system including the vehicle 102 and the drill attachment 104 are shown in various perspective views in FIGS. 2A-2C. In some embodiments, the operations of the drill attachment 104 may be controlled by remote control. This allows the operator to stand a safe distance from the worksite.

The vehicle 102 is just one type of vehicle that can be used to operate the drill attachment 104. The vehicle 102 shown helps illustrate the inventive aspects of the drill attachment 104. As depicted, the vehicle 102 is a four-wheeled vehicle operable by a user from a cab 103 and powered by an engine. In some embodiments, the vehicle 102 may be mounted to tracks instead of wheels. The engine can be a combustion engine, an electric motor, or a hybrid power system. Additionally, the engine of the vehicle 102 powers a pump that provides fluid flow to an onboard vehicle hydraulic system. The vehicle hydraulic system is configured to operate a variety of vehicle operations including the movement of a boom 106. In addition, the vehicle hydraulic system is connected to the drill attachment 104. An example of a hydraulic system for use with the drilling system 100 of the present disclosure is shown schematically in FIG. 8.

The boom 106 of the vehicle 102 includes an arm member 108 and an attachment member 110. The attachment member can 110 can pivot with respect the arm member 108, and the arm member 108 can be raised and lowered so that the attachment member 110 can be maneuvered. In some embodiments, the arm member 108 is also extendable. The attachment member can include a universal quick attachment system so as to be able to quickly couple and decouple a variety of attachments (e.g., the drill attachment 104, a bucket, a fork, etc.).

The drill attachment 104 is attached to the attachment member 110 of the boom 106 of the vehicle 102. Such attachment allows the drill attachment 104 to be raised and lowered so that the drill attachment 104 may be rested upon a large rock block in preparation for a drilling operation (see FIG. 2). The drill attachment 104 includes a main frame member 112, a stabilizing member 114, and a drill bit tower 116.

The main frame member 112 is attached to the attachment member 110 of the boom 106. In some embodiments, the main frame member 112 uses a universal quick attachment mechanism to attach to the attachment member 110. In such an embodiment, the universal attachment mechanism is configured for quick coupling and decoupling of the main frame member 112 with respect to the attachment member 110. In some embodiments, the main frame member 112 includes a pivot joint that allows the main frame member 112 to pivot at the pivot joint so as to allow for more maneuverability of the drill attachment 104.

The stabilizing member 114 is attached to the end of the main frame member 112, opposite of where the main frame member 112 is attached to the attachment member 110 of the boom 106. In the depicted embodiment, the stabilizing member 114 includes a pair of feet 118 that are configured to rest on a work surface during a drilling operation. The feet 118 of the stabilizing member 114 help to level the drill attachment 104 and also help to reduce movement of the drill attachment 104 during drilling operations.

The stabilizing member 114 also includes a pair of rails 120 to which the drill bit tower 116 is movably attached (see FIG. 2). In some embodiments, the stabilizing member 114 includes two or more rails. In other embodiments, the stabilizing member 114 includes only a single rail.

With reference to FIGS. 1 and 2, the drill bit tower 116 includes a drill bit track 122. Mounted to the drill bit tower 116 is a drill bit 124, a drill bit rotational motor 126, a percussive hammer motor 127, and a drill bit thrust motor 128. As shown in FIG. 2, the drill bit tower 116 is configured to move along the rails 120 of the stabilizing member 114 in directions D1 and D2 so as to allow the drill attachment 104 to drill a series of bores (in a linear configuration) in the work piece. During a normal drilling operation, the drill bit 124 travels in directions V1 and V2 along the drill bit tower 116 as the drill bit 124 drives into and out of a work piece.

The drill bit tower 116 provides vertical support for the drill bit 124 as the drill bit 124 progresses into a work piece during a drilling operation. Specifically, the drill bit rotational motor 126, which is mounted at a top end 130 of the drill bit 124, is mounted to a carriage 132. The carriage 132 is mounted within the drill bit track 122 and movable within the track 122 by the drill bit thrust motor 128. In the depicted embodiment, the drill bit 124 is supported with a bearing assembly 134 at a lower end 136 of the drill bit track 122. The bearing assembly 134 is configured to rest on or near the work piece so as to provide support to the drill bit 124 proximate to a drilling hole site.

The drill bit 124 can be of a variety of different sizes and made from a variety of different materials.

The drill bit rotational motor 126 is attached to the drill bit 124 so as to rotate the drill bit 124 during a drilling operation. In some embodiments, the drill bit rotational motor 126 is a hydraulic motor and operable by the hydraulic system of the vehicle 102. The drill bit rotational motor 126 can also include a pressure sensor so as to be able to monitor the operational hydraulic fluid pressure within the motor.

The percussive hammer motor 127 is also in communication with the drill bit 124. The percussive hammer motor 127 is configured to deliver a series of pulses to the drill bit 124 during a drilling operation so as to assist the drill bit 124 in drilling through rock. In the depicted embodiment, the percussive hammer motor 127 is powered by compressed air and connected to a compressor 131 that is mounted to the vehicle 102. In other embodiments, the percussive hammer motor 127 is power by a fluid, such as hydraulic fluid.

The drill bit thrust motor 128 is configured to provide a thrust force to the drill bit 124. The drill bit thrust motor 128 is a hydraulic motor that is powered by the hydraulic system of the vehicle 102. The drill bit thrust motor 128 is connected to the carriage 132 that rides within the track 122. In the depicted embodiment, the drill bit thrust motor 128 controls a chain drive that runs within the track 122. When the drill bit thrust motor is activated, it exerts a force on the carriage 132, which then exerts a force on the drill bit 124.

In some embodiments, a dust collection system 129 also may be included as part of the drill attachment 104. The dust collection system 129 is configured to remove dust from near the drilling hole worksite. The dust collection system 129 is operated by the onboard compressor 131, which creates a vacuum near the worksite hole to remove dust and small particulates from the worksite area. The dust and particulates are then routed through a conduit (not shown) to a collection area 133. In the depicted embodiment, the dust collection system 129 is positioned at an opposite end of the vehicle 102 than the drill attachment 104.

The drilling system 100 is shown schematically in FIG. 3 in a position in preparation for a drilling operation. A drilling operation is generally carried out in the following manner. In some embodiments, the drill operation can be completely automated. First, once the drill attachment 104 is attached to the vehicle 102, the vehicle 102 is positioned near a work piece 135 (e.g., a large stone block). The boom 106 of the vehicle 102 is then operated so as to lift the drill attachment 104 above the work piece 135. The boom 106 is maneuvered into position and then lowered so that the feet 118 of stabilizing member 114 of the drill attachment 104 rest on the work piece 135. The drill bit rotational motor 126, the drill bit thrust motor 128, and the dust collection system 129 are then powered up. The drill bit thrust motor 128 is then operated so to move the drill bit 124 into contact with the work piece 135 in the direction V1. Once in contact with the work piece 135, the drill bit thrust motor 128 moves the rotating drill bit 124 in the direction V1 down the drill bit tower 116 and through work piece 135 causing the drill bit 124 to bore a hole 137 through work piece 135. When a desired depth is reached by the drill bit 124 within the work piece 135, the drill bit thrust motor 128 reverses the drill bit 124 and retracts the drill bit 124 from the newly drilled hole 137 in the direction V2. In some embodiments, the drill bit rotational motor 126 is also reversed so as to rotate the drill bit 124 in a an opposite direction from the drilling direction. Once removed from the hole 137, the drill bit tower 116 moves along the rails 120 of the stabilizing member (e.g., in the direction D1 as shown in FIG. 2) so as to prepare for a new drilling operation. Once a desired distance is reached from the first drilled hole 137, the drill operation is repeated in its entirety. This process is repeated until a desired amount of holes are bored in the work piece 135. The drill attachment 104 and vehicle 102 can then be removed from the work piece 135, and the work piece 135 can be split.

In operating the drill attachment 104 during the drilling operation, the drill attachment 104 includes a control system 138 that monitors a variety of different parameters and controls the function of the components of the drill attachment 104.

FIG. 4 shows a schematic representation of the control system 138 of the drill attachment 104. The control system 138 is in overall communication with the vehicle 102. This is so that the control system 138 can monitor the operational parameters of the vehicle 102, specifically the hydraulic system. While the control system 138 controls operational aspects of the drilling attachment 104, it also includes a detection system that helps to reduce failure and damage to the drill attachment 104 during certain events that can occur during the drilling operation.

The control system 138 monitors the drill attachment 104 for a broken drill bit event 140, a drill bit blow-out event 142, and a pressure loss event 144. Upon recognizing the presence of any one of these events, the control system 138 stops the drill bit rotational motor 126, the percussive hammer motor 127, and the drill bit thrust motor 128. After the percussion, thrust, and rotation are stopped, the control system 138 returns the drill bit 124 of the drill attachment 104 to a home/neutral position. The home position can be predefined by the user to be a position outside of the hole the drill bit 124 is currently boring, or it could be a position of the drill bit 124 prior the event being sensed by the control system 138 (i.e., a safe position).

FIG. 5 shows schematic representation of the operation of the control system 138 when monitoring for a blow-out event 142. Due to the deflection imparted on the drill bit 124 when the drill bit 124 encounters a blow-out event 142, the operating pressure in the vehicle's hydraulic system incurs a spike. This spike is caused by an increased load in the drill bit rotational motor 126 or the drill bit thrust motor 128 as both motors attempt to continue to bore a hole while the drill bit 124 is experiencing a deflection caused by the blow-out event 142.

Therefore, in order to monitor for a blow-out event 142, the control system 138 monitors the operating pressure in the hydraulic system 144. The control system 138 then compares the operating pressure of the hydraulic system to a predetermined pressure value at step 146. The predetermined pressure value is set by the user and this value can depend on the type of drill bit 124 being used, the type of rock the drill bit 124 is being operated in, current weather conditions, other loads on the hydraulic system, and a variety of other factors. In some embodiments, the predetermined value is a change in operational pressure. This allows the system to take into consideration a momentary pressure spike that may be caused by a blow-out event. If the operating pressure exceeds the predetermined value at step 148, the control system 138 will promptly stop percussion, thrust, and rotation at step 150 and return the drill bit to the home position at step 152.

In some embodiments, after the operating pressure exceeds the predetermined value, the control system 138 can also sound an alarm at step 154. If the operating pressure does not exceed the predetermined value at step 156, the control system 138 continues the drilling operation at step 158.

FIG. 6 shows schematic representation of the operation of the control system 138 in monitoring for a broken drill bit event 140. When a drill bit 124 breaks during a drilling operation, operational pressure drops and progression of the drill bit 124 within the work piece slows considerably.

Therefore, in order to monitor for a broken drill bit event 140, the control system 138 monitors the rate of progression of the drill bit at step 160 along with the operating pressure in the hydraulic system at step 162. To monitor the rate of progression, the control system 138 can include a sensor on the drill bit tower 116 and/or the drill bit thrust motor 128. In some embodiments, the control system 138 can monitor the progression of the carriage 132 within the track 122 of the drill bit tower 116.

The control system 138 then compares the rate of progression of the drill bit 124 with a predetermined rate value, and also compares the operating pressure of the hydraulic system to a predetermined pressure value at step 164. As noted above, the predetermined values are normally set by the user and can depend on a variety of different factors. If both the operating pressure and rate of progression drop below their corresponding predetermined values at step 166, the control system 138 will promptly stop percussion, thrust, and rotation at step 168 and return the drill bit to the home position at step 170.

In some embodiments, the control system 138 can also sound an alarm at step 172. If both the operating pressure and rate of progression do not drop below their corresponding predetermined values at step 174, the control system 138 continues the drilling operation at step 176.

FIG. 7 shows schematic representation of the operation of the control system 138 when monitoring for a pressure loss event 144. If a loss of air pressure occurs in the system, the percussive hammer motor 127 is likely to malfunction. A loss of air pressure can occur if there is a malfunction with the compressor 131 that powers the percussive hammer motor 127, if there is a broken/unattached hose in the system, or any other malfunction in the compressed air system. This can lead the drill bit 124 to operate without percussive force, which can decrease its drilling effectiveness when drilling in rock. Additionally, without percussion, the drill bit 124 may wear more rapidly.

Therefore, in order to monitor for a pressure loss event 144, the control system 138 monitors the operating air pressure in the percussive hammer motor at step 178. The control system 138 then compares the operating air pressure in the percussive hammer motor to a predetermined pressure value at step 180. The predetermined pressure value is set by the user and its value can depend on a variety of factors, such as the recommended operating parameters of the components within the percussive hammer motor 127. If the operating air pressure drops below the predetermined value at step 182, the control system 138 will promptly stop percussion, thrust, and rotation at step 184 and return the drill bit to the home position at step 186.

In some embodiments, after the operating air pressure drops below the predetermined value at step 182, the control system 138 can also sound an alarm at step 188. If the operating air pressure does not drop below the predetermine value at step 190, the control system 138 continues the drilling operation at step 192.

FIG. 8 schematically illustrates an example hydraulic circuit broken into separate pages for use with the drilling system 100. In some examples, the hydraulic system 100 utilizes a plurality of different valve assemblies for different operations of the hydraulic system 100. In some examples, the lateral and vertical movement can be controlled at least partially by separate valve assemblies. In other examples, the lateral and vertical movement can be controlled at least partially by the same valve assembly. In some examples, the drill rotation and drill percussion are controlled in the same valve assembly.

The various embodiments described above are provided by way of illustration only and should not be construed to limit the claims attached hereto. Those skilled in the art will readily recognize various modifications and changes that may be made without following the example embodiments and applications illustrated and described herein, and without departing from the true spirit and scope of the following claims. 

What is claims is:
 1. A method of using a hydraulic system of a percussive drill as a sensing system, the method comprising: sensing a drill bit blow-out event by measuring changes in the operating hydraulic fluid pressure in the hydraulic system used to operate the percussive drill.
 2. The method of claim 1, further comprising stopping the percussive drill operation if the change in operating hydraulic fluid pressure has a pressure spike exceeding a predetermined pressure value.
 3. The method of claim 2, further comprising retracting a drill bit attached to the percussive drill after stopping the percussive drill operation.
 4. The method of claim 1, further comprising sensing a system failure event by monitoring a pressure loss within the hydraulic system.
 5. The method of claim 4, wherein the system failure event is a broken drill bit event.
 6. The method of claim 1, further comprising sounding an audible alarm when a blow-out event is sensed.
 7. The method of claim 1, further comprising sensing a broken drill bit event by measuring changes in the rate of cut by the percussive drill.
 8. A drilling attachment configured to attach to a vehicle, the drilling attachment comprising: a drill bit; a first motor for rotating the drill bit; a second motor for controlling the thrust applied to the drill bit, wherein the first and second motors include hydraulic connections for attaching to an external hydraulic system; and a drill bit blow-out sensing system being operatively connected to the first and second motors, wherein the drill bit blow-out sensing system senses a drill bit blow-out event based on a change in an operational hydraulic pressure within at least one of the first and second motors.
 9. The drilling attachment of claim 8, further comprising a dust collection system for removing dust near the drill bit, the dust collection system including a compressor.
 10. The drilling attachment of claim 8, wherein the drill bit blow-out sensing system compares the change in the operational hydraulic pressure to a predetermined value, and wherein the drill bit blow-out sensing system stops the operation of the drill bit if the change in operational hydraulic pressure exceeds the predetermined value.
 11. The drilling attachment of claim 8, wherein the drill bit blow-out sensing system also senses a broken drill bit event by monitoring a hydraulic pressure loss within at least one of the first and second motors.
 12. The drilling attachment of claim 8, wherein the drill bit blow-out sensing system is configured to sound an audible alarm when a blow-out event is sensed.
 13. A drill bit monitoring system for a percussive drill comprising: a vehicle including: an engine; a hydraulic system having a pump at least partly powered by the engine; and a boom operated by the hydraulic system; a drilling attachment removably attached to the boom of the vehicle, the drilling attachment including: a drill bit; a first motor for rotating the drill bit; a second motor for controlling the thrust applied to the drill bit, wherein the first and second motors are connected to the hydraulic system of the vehicle; and a drill bit blow-out sensing system being operatively connected to the first and second motors, wherein the drill bit blow-out sensing system senses a drill bit blow-out event based on a change in an operational hydraulic pressure within at least one of the first and second motors.
 14. The drill bit monitoring system of claim 13, further comprising a dust collection system for removing dust near the drill bit, the dust collection system including a compressor.
 15. The drill bit monitoring system of claim 13, wherein the drill bit blow-out sensing system is an integral part of the hydraulic system of the vehicle.
 16. The drill bit monitoring system of claim 13, wherein the drill bit blow-out sensing system compares the change in the operational hydraulic pressure to a predetermined value, and wherein the drill bit blow-out sensing system stops the operation of the drill bit if the change in operational hydraulic pressure exceeds the predetermined value.
 17. The drill bit monitoring system of 13, wherein the drill bit blow-out sensing system also senses a broken drill bit event by monitoring an operational hydraulic pressure loss within at least one of the first and second motors.
 18. The drill bit monitoring system of 13, wherein the drill bit blow-out sensing system is configured to sound an audible alarm when a blow-out event is sensed. 